Heat Exchange System Housings

ABSTRACT

The present application discloses embodiments of a housing configured for use in a heat exchange system. The housing includes one or more side panels with a plurality of openings. The openings each define a cross-sectional area and create a passageway through the side panel. The openings can include a first series of openings that includes all of the openings located within a bottom third portion of the side panel, a second series of openings that includes all of the openings within a middle third portion of the side panel, and a third series of openings that includes all of the openings located within a top third portion of the side panel, wherein the cumulative cross-sectional area of the first series of openings is greater than the cumulative cross-sectional area of the second series of openings which is greater than the cumulative cross-sectional area of the third series of openings.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit to U.S. Provisional Application No. 61/596,454, filed Feb. 8, 2012, the disclosure of which is hereby incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to enclosures for systems with air intake and exhaust components. More specifically, the present disclosure relates to a housing for use with heat exchanging systems.

BACKGROUND

HVAC (heating, ventilation, and air conditioning) refers to the technology used for enhancing indoor or automotive environmental comfort. HVAC system design relies on the principles of thermodynamics, fluid mechanics, and heat transfer.

In HVAC systems involving heat transfer, a condenser is a device or unit often used to condense a substance from its gaseous to its liquid state, typically by cooling it. During the phase change of the substance from its gaseous state to its liquid state, latent heat is given up by the substance, and the heat will transfer to a coolant in the condenser. Condensers can have various designs and come in many sizes ranging from small (for example, hand-held) to very large industrial-scale units used in plant processes. Condensers are used in a wide variety of applications ranging from residential air conditioning to industrial chemical processes such as distillation, steam power plants and other heat-exchange systems.

A condenser unit used in central air conditioning systems typically has a heat exchanger section to cool and condense incoming refrigerant vapor into liquid, a compressor to raise the pressure of the refrigerant and move it through the condenser, and a fan to move outside air through and/or over the heat exchanger section to cool the refrigerant inside. A typical configuration of a condenser unit can include a heat exchanger section wrapped around the sides of the unit with a compressor inside. The refrigerant passes through multiple tubes, which are surrounded by heat transfer fins. A motorized fan positioned, for example, inside the condenser unit (typically near the top of the unit) pulls cooling air into the unit and moves the air across the refrigerant tubes and then out of the unit.

Typically the cooling air enters the condenser unit through its sides. The sides of the unit can be covered with a grating that contains louvers and acts to protect the inner components of the condenser and direct air into the unit. The cooling air then passes over the refrigerant tubes and is exhausted from the unit through the top of the unit. It has been recognized in connection with the present inventions that the louvers in conventional enclosures for heat exchanging systems allow the cooling air to enter the system much more efficiently at the top of the side panels than at the bottom of the side panels. This results in increased air flow over the refrigerant tubes at the top of the system and poor air flow over the refrigerant tubes at the bottom of the system. An enclosure for a heat exchanging system that directs the cooling air to enter the system more evenly could increase the efficiency of the heat exchanging system.

SUMMARY

Various embodiments of housings configured for use in a heat exchange system are disclosed. In one embodiment, the housing includes a panel that has an outer surface and an opposed inner surface, the outer and inner surfaces each extending from a top edge to a bottom edge. The panel has a top portion that includes the top edge, a bottom portion that includes the bottom edge, and a middle portion positioned between the top portion and the bottom portion. The panel further includes a plurality of openings that extend from the outer surface to the inner surface such that each of the plurality of openings defines a cross-sectional area and creates a passageway through the panel. The plurality of openings include a first series of openings that includes all of the openings located within the bottom portion, a second series of openings that includes all of the openings within the middle portion, and a third series of openings that includes all of the openings located within the top portion. The cumulative cross-sectional area of the first series of openings is greater than the cumulative cross-sectional area of the second series of openings and the cumulative cross-sectional area of the second series of openings is greater than the cumulative cross-sectional area of the third series of openings.

In another embodiment, the housing includes a panel with an outer surface and an opposed inner surface, the outer and inner surfaces each extending from a top edge to a bottom edge. The panel further including a plurality of openings that extend from the outer surface to the inner surface such that each of the plurality of openings defines a cross-sectional area and creates a passageway through the panel, wherein the cross-sectional area of the plurality of openings gradually decreases from the bottom edge to the top edge such that the average cross-sectional area of the plurality of openings near a halfway point between the top edge and the bottom edge is: (1) greater than the average cross-sectional area of the plurality of openings near the top edge and (2) less than the average cross-sectional area of the plurality of openings near the bottom edge.

Heat exchange systems are also disclosed. The heat exchange systems can include a compressor, a heat exchanger, an exhaust fan, and a housing that encloses at least the heat exchanger. The housings include one or more panels, each of the one or more panels having an outer surface and an opposed inner surface, the outer and inner surfaces each extending from a top edge to a bottom edge, and the one or more panels further including a plurality of openings that extend from the outer surface to the inner surface such that each of the plurality of openings defines a cross-sectional area and creates a passageway through the one or more panels. The plurality of openings include a first series of openings positioned near the bottom edge, a second series of openings positioned near a halfway point between the top edge and the bottom edge, and a third series of openings positioned near the top edge, and the cumulative cross-sectional area of the first series of openings is greater than the cumulative cross-sectional area of the second series of openings and the cumulative cross-sectional area of the second series of openings is greater than the cumulative cross-sectional area of the third series of openings, such that as the exhaust fan draws air into the condenser the air passes through the plurality of openings and passes substantially evenly over the heat exchanger near both the top edge and the bottom edge.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description of the preferred embodiments, will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the housings and heat exchange systems, there is shown in the drawings preferred embodiments. It should be understood, however, that the present disclosure is not limited to the specific embodiments disclosed, and reference is made to the claims for that purpose. In the drawings:

FIG. 1 is a front view of a heat exchanging system according to the prior art;

FIG. 2 is a front view of a heat exchanging system including a panel according to one embodiment;

FIG. 3 is a front view of the heat exchanging system illustrated in FIG. 2, the system including a panel according to another embodiment;

FIG. 4 is a front view of the heat exchanging system illustrated in FIG. 2, the system including a panel according to another embodiment;

FIG. 5 is a perspective, sectional view of the heat exchanging system illustrated in FIG. 2, the system including a panel according to another embodiment, a compressor, a heat exchanger and an exhaust fan;

FIG. 6 is a front view of a housing configured to be retrofit over an existing heat exchanging system.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Certain terminology is used in the following description for convenience only and is not limiting. The words “front,” “rear,” “right,” “left,” “lower,” and “upper” designate directions in the drawings to which reference is made. The term “plurality,” as used herein, means more than one. Certain features of the invention which are described herein in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features of the invention that are described in the context of a single embodiment may also be provided separately or in any subcombination.

Referring to FIG. 1, a heat exchanging unit 10 includes a conventional housing 12. The conventional housing 12 includes at least one side panel 14 and a top panel 16. The side panel 14 includes a plurality of louvers (or openings) 18. As shown, the louvers 18 are evenly spaced throughout the side panel 14 and are also all the same size and shape. The top panel 16 houses a fan 20. When the fan 20 is turned on, air is pulled into the unit 10 through the louvers 18 in the side panel 14 and exhausted out of the unit 10 through an opening 22 in the top panel 16. However, due to the size and location of the louvers 16, the air flow through the louvers 18 located closest to the fan 20 (arrow AF1) is greater than the air flow through the louvers 18 located furthest from the fan 20 (arrow AF2).

Referring to FIG. 2, a heat exchanging unit 110 includes a housing 112 according to one embodiment of the present disclosure. The housing can include at least one side panel 114 and a top panel 116. The side panel 114 can include an outer surface 124, an opposed inner surface (126—see FIG. 5) and plurality of openings 118. The outer and inner surfaces 124, 126 each extend vertically from a bottom edge 128 to a top edge 130, the distance between the bottom edge 128 and the top edge 130 defining a height H. Each of the openings 118 can extend from the outer surface to the inner surface such that each of the openings define a cross-sectional area and create a passageway through the side panel 114. The top panel 116 can house a fan 120. When the fan 120 is turned on air is pulled into the unit 10 through the openings 118 in the side panel 114. The air passes over the internal heat exchanging components (not shown) and is then exhausted out of the unit 110 by the fan 120 through an opening 122 in the top panel 116.

As shown, the plurality of openings 118 can be of different sizes. In one embodiment, the openings 118 are arranged into rows of openings. A row (or series) of openings is defined as a plurality of openings 118 at substantially the same height (measured as the distance from the bottom edge 128). The first row of openings 131 is located closest to the bottom edge 128 of the unit 110. The second row of openings 132 is located adjacent to and above the first row of openings 131 such that the first row of openings 131 is closer to the bottom edge 128 and the second row of openings 132 is closer to the top edge 130. Additional rows can be included with each successive row being positioned above the previous row.

As shown, a third row of openings 133 is positioned above the second row of openings 132, a fourth row of openings 134 is positioned above the third row of openings 133, a fifth row of openings 135 is positioned above the fourth row of openings 134, a sixth row of openings 136 is positioned above the fifth row of openings 135, a seventh row of openings 137 is positioned above the sixth row of openings 136, an eighth row of openings 138 is positioned above the seventh row of openings 137, and a ninth row of openings 139 is positioned above the eighth row of openings 138. One skilled in the art will understand that the exact number of rows can be varied from one embodiment to another.

In one embodiment, the openings 118 within each row are all substantially the same size and shape. In another embodiment the size and shape of the openings 118 within the same row can be varied. Each of the openings 118 defines a cross-sectional area such that the cumulative cross-sectional area of each row of openings is greater than the cross-sectional area of each of the rows of openings above it and less than the cumulative cross-sectional area of each of the rows of openings below it. For example, the cumulative cross-sectional area of the first row of openings 131 is greater than the cumulative cross-sectional area of the second row of openings 132 and the cumulative cross-sectional area of the second row of openings 132 is greater than the cumulative cross-sectional area of the third row of openings 133. Thus it can be said that the cross-sectional area of the plurality of openings 118 gradually decreases from the bottom edge 128 to the top edge 130 such that the cumulative cross-sectional area of the plurality of openings near a halfway point between the top edge 130 and the bottom edge 128 is greater than the cumulative cross-sectional area of the plurality of openings near the top edge 130 and less than the cumulative cross-sectional area of the plurality of openings near the bottom edge 128.

The side panel 114 can further define a plurality of portions. For example, the side panel 114 can include three portions that each include a third of the height H of the side panel measured from the bottom edge 128 to the top edge 130. In one embodiment the side panel 114 defines: a bottom third portion 141 that extends from the bottom edge 128 upward a third of the height H toward the top edge 130 and terminates at section line 146; a top third portion 143 that extends from the top edge 130 downward a third of the height H toward the bottom edge 128 and terminates at section line 148; and a middle third portion 142 that extends from the top of the bottom third portion 141 (section line 146) upward a third of the height H to the bottom of the top third portion 143 (section line 148). It will be apparent to one skilled in the art that the exact number of portions can be varied from one embodiment to another.

According to one embodiment, the plurality of openings 118 can include a first series of openings 151 that includes all of the openings 118 located within the bottom third portion 141, a second series of openings 152 that includes all of the openings 118 within the middle third portion 142, and a third series of openings 153 that includes all of the openings 118 located within the top third portion 143. As shown, the cumulative cross-sectional area of the first series of openings 151 can be greater than the cumulative cross-sectional area of the second series of openings 152 and the cumulative cross-sectional area of the second series of openings 152 can be greater than the cumulative cross-sectional area of the third series of openings 153. According to one embodiment, the number of openings 118 in each row of openings can be the same. As shown, the first row of openings 131 has the same number of openings 118 as the second row of openings 132.

Referring to FIG. 3, in another embodiment of the heat exchanging unit 110, the side panel 114 can include multiple series of openings each with varying numbers of openings 118 from series to series such that the average cross-sectional area of the first series of openings 151 can be greater than the average cross-sectional area of the second series of openings 152 and the average cross-sectional area of the second series of openings 152 can be greater than the average cross-sectional area of the third series of openings 153.

Referring to FIG. 4, in another embodiment of the heat exchanging unit 110, the side panel 114 can include multiple series of openings each with varying shapes of openings 118. The average cross-sectional area of the first series of openings 151 can be greater than the average cross-sectional area of the second series of openings 152 and the average cross-sectional area of the second series of openings 152 can be greater than the average cross-sectional area of the third series of openings 153.

Referring to FIG. 5, another embodiment heat exchange unit 110 can include a compressor 170 and a heat exchanger 172 including a plurality of refrigerant tubes 174 disposed within a housing 112. The housing 112 can include one or more side panels 114, each of the one or more side panels 114 including an outer surface 124 and an opposed inner surface 126, the outer and inner surfaces 124, 126 each extending from a bottom edge 128 to a top edge 130. The one or more side panels 114 can further include a plurality of openings 118 that extend from the outer surface 124 to the inner surface 126 such that each of the plurality of openings 118 defines a cross-sectional area and creates a passageway through the one or more side panels 114. The plurality of openings 118 can include a first series of openings 151 positioned near the bottom edge 128, a second series of openings 152 positioned near a halfway point between the top edge 130 and the bottom edge 128, and a third series of openings 153 positioned near the top edge 130, and wherein the cumulative cross-sectional area of the first series of openings 151 is greater than the cumulative cross-sectional area of the second series of openings 152 and the cumulative cross-sectional area of the second series of openings 152 is greater than the cumulative cross-sectional area of the third series of openings 153, such that as the exhaust fan 120 draws air into the heat exchanger unit 110 the air passes through the plurality of openings 118 such that air passes substantially evenly over the heat exchanger 172 near both the top edge 130 and the bottom edge 128.

As shown, air is pulled into the heat exchanging unit 110 through the openings 118 in the one or more side panels 114. The air then passes over the refrigerant tubes 174 of the heat exchanger 172 removing heat from the heat exchanger 172. The air and excess heat are then exhausted by the exhaust fan 120 through an opening 122 in the top panel 116 of the unit 110. The size and arrangement of the first, second and third series of openings 151, 152, 153 are configured to promote increased air flow over the refrigerant tubes 174 near the bottom edge 128. Preferably the air flow through the first series of openings 151 located closest to the bottom edge 128 (arrow AF2) is substantially equal to the air flow through the second series of openings 152 located closest to the top edge 130 (arrow AF1). The size, shape, placement, or number of the plurality of openings 118, or any combination thereof, can vary to adjust the ratio of the airflow AF1 to the airflow AF2. In one embodiment the plurality of openings 118 can be configured such that the airflow AF1 is less than the airflow AF2. In yet another embodiment the plurality of openings 118 can be configured such that the airflow AF1 is greater than the airflow AF2.

Referring to FIG. 6, the housing 112 can be separate from (or non-integral with) the rest of a heat exchanging unit. In one embodiment, as shown in the illustrated embodiment, the housing 112 is configured to be placed around an existing heat exchanging unit in order to retrofit the existing heat exchanging unit such that the air flow characteristics into and through the heat exchanging unit are changed. In another embodiment the housing 112 can be configured to fit within the existing exterior facade of a conventional heat exchanging unit. This would allow the conventional heat exchanging unit to maintain its established exterior appearance while gaining the benefit of the airflow characteristics provided by the plurality of openings 118 as described in detail above. The exact location of the housing 112 within the heat exchanging unit can be chosen based on criteria such as ease of manufacturing and cost. In one embodiment, the housing 112 can be positioned just inside the exterior facade of the heat exchanging unit, for instance between the facade and the heat exchanger. Alternately, the housing 112 can be placed further inside the heat exchanging unit 110, for instance between the heat exchanger and the fan.

As shown in the illustrated embodiment the housing 112 can be curved (such that the housing 112 is a circular or other tubular shape). In another embodiment the housing 112 can include a single side panel 114. In yet another embodiment the housing 112 can be any desired shape that corresponds to or fits around or within an existing heat exchanging unit. The housing 112 can include a plurality of side panels 114 necessary to create the desired shape. The non-integral housing 112 can include any of the disclosed embodiments of the plurality of rows or series of openings (or any combination thereof) described in detail above.

It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this disclosure is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present disclosure as defined by the claims. 

What is claimed:
 1. A housing configured for use in a heat exchange system, the housing comprising a panel that includes: an outer surface and an opposed inner surface, the outer and inner surfaces each extending from a top edge to a bottom edge; a top third portion that includes the top edge, a bottom third portion that includes the bottom edge, and a middle third portion positioned between the top third portion and the bottom third portion; and a plurality of openings that extend from the outer surface to the inner surface such that each of the plurality of openings defines a cross-sectional area and creates a passageway through the panel; wherein: the plurality of openings include a first series of openings that includes all of the openings located within the bottom third portion, a second series of openings that includes all of the openings within the middle third portion, and a third series of openings that includes all of the openings located within the top third portion; and the cumulative cross-sectional area of the first series of openings is greater than the cumulative cross-sectional area of the second series of openings and the cumulative cross-sectional area of the second series of openings is greater than the cumulative cross-sectional area of the third series of openings.
 2. The housing of claim 1, wherein the outer surface of the panel is curved such that the panel is cylindrical in shape.
 3. The housing of claim 1, wherein the panel further is configured to be connected to additional panels to form an enclosure.
 4. The housing of claim 3, wherein the enclosure is a square or rectangular shape.
 5. The housing of claim 1, wherein the cross-sectional area of each of the openings in the first series of openings is larger than the cross-sectional area of each of the openings in the second series of openings.
 6. The housing of claim 5, wherein the cross-sectional area of each of the openings in the second series of openings is larger than the cross-sectional area of each of the openings in the third series of openings.
 7. The housing of claim 1, wherein the number of openings in the first series of openings is greater than the number of openings in the second series of openings.
 8. The housing of claim 7, wherein the number of openings in the second series of openings is greater than the number of openings in the third series of openings.
 9. The housing of claim 1, wherein each of the plurality of openings has a shape and the shape of each of the plurality of openings is the same.
 10. The housing of claim 1, wherein each of the plurality of openings has a shape and the shape of at least two of the plurality of openings is different.
 11. The housing of claim 1, wherein the housing encloses a condenser of the air conditioning system.
 12. The housing of claim 11, wherein the housing is integral with the condenser.
 13. The housing of claim 11, wherein the housing is configured to be placed at least partially around an existing housing of the condenser.
 14. The housing of claim 11, wherein the housing is configured to be placed within an existing condenser.
 15. The housing of claim 1, wherein the cross-sectional area of each of the plurality of openings is (1) greater than the cross-sectional area of each of the plurality of openings positioned closer to the top edge and (2) less than the cross-sectional area of each of the plurality of openings positioned closer to the bottom edge.
 16. The housing of claim 1, wherein the heat exchange system is an air conditioning system.
 17. A housing configured for use in a heat exchange system, the housing comprising: a panel including an outer surface and an opposed inner surface, the outer and inner surfaces each extending from a top edge to a bottom edge, the panel further including a plurality of openings that extend from the outer surface to the inner surface such that each of the plurality of openings defines a cross-sectional area and creates a passageway through the panel; wherein the cross-sectional area of the plurality of openings gradually decreases from the bottom edge to the top edge such that the average cross-sectional area of the plurality of openings near a halfway point between the top edge and the bottom edge is: (1) greater than the average cross-sectional area of the plurality of openings near the top edge and (2) less than the average cross-sectional area of the plurality of openings near the bottom edge.
 18. The housing of claim 17, wherein the cross-sectional area of each of the plurality of openings is (1) greater than the cross-sectional area of each of the plurality of openings positioned closer to the top edge and (2) less than the cross-sectional area of each of the plurality of openings positioned closer to the bottom edge.
 19. The housing of claim 17, wherein the heat exchange system is an air conditioning system.
 20. A heat exchange system comprising: a compressor; a heat exchanger; an exhaust fan; and a housing that encloses at least the heat exchanger and includes one or more panels, each of the one or more panels including an outer surface and an opposed inner surface, the outer and inner surfaces each extending from a top edge to a bottom edge, the one or more panels further including a plurality of openings that extend from the outer surface to the inner surface such that each of the plurality of openings defines a cross-sectional area and creates a passageway through the one or more panels; wherein the plurality of openings include a first series of openings positioned near the bottom edge, a second series of openings positioned near a halfway point between the top edge and the bottom edge, and a third series of openings positioned near the top edge, and wherein the cumulative cross-sectional area of the first series of openings is greater than the cumulative cross-sectional area of the second series of openings and the cumulative cross-sectional area of the second series of openings is greater than the cumulative cross-sectional area of the third series of openings, such that as the exhaust fan draws air into the heat exchange system the air passes through the plurality of openings and passes substantially evenly over the heat exchanger near both the top edge and the bottom edge.
 21. The housing of claim 20, wherein the heat exchange system is an air conditioning system.
 22. A process comprising the steps of: providing a heat exchanger; and positioning said heat exchanger within a housing according to claim
 1. 23. The process of claim 22, wherein the heat exchanger is a component of a heat exchange system comprising a compressor and exhaust fan and said positioning step positions said compressor and said exhaust fan within said housing. 